Modular furnace cooling wall

ABSTRACT

A modular furnace cooling wall, comprising: a plurality of segments wherein each interior segment houses or defines a cooling fluid conduit having an inlet and an outlet; wherein a first side of each segment defines a concave groove or channel; wherein a second side of each segment defines a convex edge; and wherein the plurality of segments are assembled so that the convex edge of one or more of the segments is received within the concave groove of an adjacent segment.

This application claims the benefit of provisional patent applicationU.S. Ser. No. 62/416,800 filed Nov. 3, 2016, which is incorporated byreference herein for all purposes.

FIELD OF THE DISCLOSURE

The present disclosure is related to apparatus and methods for coolingthe furnace shell of blast furnaces and other metallurgical furnaces.Related fields include cooling staves.

BACKGROUND OF THE DISCLOSURE

Generally there exist two principal types of cooling systems for blastfurnaces or electric arc furnaces. These two cooling systems have beencooling plates and cooling staves, each with their own advantages anddisadvantages.

Conventional cooling plates are tongue shaped coolers which protrudethrough a single hole in the steel furnace shell and stick into thevessel on average approximately 24 inches and are approximately 24inches wide. Such plates are securely fastened to the steel shell andthe plates are connected to an external cooling source.

Staves are elements placed between the inner side of the steel shell ofa furnace and the refractory lining. The staves are typically formedwith a series of tubes to carry a heat transfer fluid, such as water.The staves can cool a furnace uniformly as they may be installed to havealmost complete steel shell coverage. Typical stave coolers areapproximately 30″ to 50″ wide by 48″ to 144″ tall. These staves aretypically bolted to the furnace wall and may have small gaps betweenthem to allow for installation.

In order to overcome the disadvantages associated with typical furnacecooling plates and cooling staves, it would be desirable to provide amodular furnace cooling wall comprising a plurality of generallyrectilinear or any shaped interior segments wherein each interiorsegment houses or defines its own cooling fluid conduit or circuithaving a cooling fluid inlet and a cooling fluid outlet.

It would also be desirable to provide a modular furnace cooling wallthat provides simplified assembly, reduced copper wall thickness, lessoverall weight due to reduced casting sizes but with all the benefits oflarge cast furnace panels.

BRIEF SUMMARY OF THE DISCLOSURE

Many other variations are possible with the present disclosure, andthose and other teachings, variations, and advantages of the presentdisclosure will become apparent from the description and figures of thedisclosure.

One aspect of a preferred embodiment of the present disclosure comprisesa modular furnace cooling wall, comprising: a plurality of segmentswherein each interior segment houses or defines a cooling fluid conduithaving an inlet and an outlet; wherein a first side of each segmentdefines a concave groove or channel; wherein a second side of eachsegment defines a convex edge; and wherein the plurality of segments areassembled so that the convex edge of one or more of the segments isreceived within the concave groove of an adjacent segment.

In another aspect, the modular furnace cooling wall further comprisesone or more end segments having a first side defining either a concavegroove or channel or a convex edge and a second side defining agenerally flat surface.

In another aspect of a preferred modular furnace cooling wall of thepresent disclosure, at least one of the one or more end segments isassembled to an outer side of an assembled segment, wherein thegenerally flat surface of the end segment is disposed as an outer narrowsidewall of the modular furnace cooling wall.

In another aspect of a preferred modular furnace cooling wall of thepresent disclosure, the first side of each of the one or more endsegments defining either a concave groove or channel or a convex edge isassembled to a mating side of one of the plurality of segments.

In another aspect, the modular furnace cooling wall further comprises amounting plate or bracket to which each of the segments is removablypinned or otherwise removably attached.

In another aspect, the modular furnace cooling wall further comprisesone or more support braces or brackets removably attached to one or moreof the segments or end segments.

In another aspect of a preferred modular furnace cooling wall of thepresent disclosure, the modular furnace cooling wall defines a curvedwall, a semi-circular wall, a circular wall or an enclosed wall theperimeter of which defines a geometric or non-geometric shape.

In another aspect, the modular furnace cooling wall further comprises acooling fluid manifold in fluid communication with the inlet and outletof each segment.

In another aspect, the modular furnace cooling wall further comprises acooling fluid manifold in fluid communication with the inlet and outletof each segment and end segment.

Another aspect of a preferred embodiment of the present disclosurecomprises an interior segment of a modular furnace cooling wall, theinterior segment comprising: a housing which defines and houses acooling fluid conduit having an inlet and an outlet; a first side of thehousing defining a concave groove or channel; and a second side of thehousing defining a convex edge.

Yet another aspect of a preferred embodiment of the present disclosurecomprises an end segment for a modular furnace cooling wall, the endsegment comprising: a generally rectilinear housing which defines andhouses a cooling fluid conduit having an inlet and an outlet; a firstside of the housing defining either a concave groove or channel or aconvex edge; and a second side defining a generally flat surface.

Another aspect of a preferred embodiment of the present disclosurecomprises a modular furnace cooling wall, comprising: a plurality ofgenerally rectilinear wall segments wherein each wall segment houses ordefines a cooling fluid conduit having an inlet and an outlet; whereineach wall segment has planar first and second sides that are eachbeveled; and wherein the plurality of wall segments are assembled andsecured together to form a straight, curved, angled or enclosed wall.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For the present disclosure to be easily understood and readilypracticed, the present disclosure will now be described for purposes ofillustration and not limitation in connection with the followingfigures, wherein:

FIG. 1A shows an exterior top, perspective view of a preferred modularfurnace cooling wall having a cut-out section for a burner housingaccording to the present disclosure;

FIG. 1B shows an exterior top, perspective view of a modular furnacecooling wall having a burner housing installed in a cut-out sectionaccording to the present disclosure;

FIG. 2A shows an interior top, perspective view of a modular furnacecooling wall having a cut-out section for a burner housing according tothe present disclosure;

FIG. 2B shows an interior top, perspective view of a modular furnacecooling wall having a burner housing installed in a cut-out sectionaccording to the present disclosure;

FIG. 3 shows a top, perspective view of individual cooling segmentsmaking up a modular furnace cooling wall according to the presentdisclosure;

FIG. 4 shows a top, perspective view of an individual cooling segmentfor use in making up a modular furnace cooling wall according to thepresent disclosure;

FIG. 5 shows a top, perspective view of an individual end coolingsegment (cooling fluid inlet and cooling fluid outlet not shown) for usein making up a modular furnace cooling wall according to the presentdisclosure;

FIG. 6 shows a top, perspective view of an individual interior coolingsegment (cooling fluid inlet and cooling fluid outlet not shown) for usein making up a modular furnace cooling wall according to the presentdisclosure;

FIG. 7 shows an interior perspective view of a modular furnace coolingwall according to the present disclosure;

FIG. 8 shows an exterior perspective view of a modular furnace coolingwall according to the present disclosure;

FIG. 9 shows a modular furnace cooling wall forming an enclosedperimeter of a generally hexagonal shape according to the presentdisclosure comprising a plurality of wall segments wherein each wallsegment has planar first and second sides that are each preferablybeveled; and

FIG. 10 shows an individual cooling segment used in making up themodular furnace cooling wall forming an enclosed perimeter of FIG. 9.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying examples and figures that form a part hereof, and in whichis shown by way of illustration specific embodiments in which theinventive subject matter may be practiced. These embodiments aredescribed in sufficient detail to enable those skilled in the art topractice them, and it is to be understood that other embodiments may beutilized and that structural, logical, and electrical changes may bemade without departing from the scope of the inventive subject matter.Such embodiments of the inventive subject matter may be referred to,individually and/or collectively, herein by the term “disclosure” merelyfor convenience and without intending to voluntarily limit the scope ofthis application to any single disclosure or inventive concept if morethan one is in fact disclosed.

The following description is, therefore, not to be taken in a limitedsense, and the scope of this disclosure is defined by the appendedclaims.

A preferred modular furnace cooling wall 10, such as for an EAF(Electric Arc Furnace), blast furnace or other type of metallurgicalfurnace, of the present disclosure, comprises: a plurality of generallyrectilinear or any shaped interior segments 20 wherein each interiorsegment houses or defines a cooling fluid conduit or circuit (such aspiping or drilled and plugged design) having an inlet 24 and an outlet26; wherein a first side of each interior segment defines a concavegroove or channel 23; wherein a second side of each interior segmentdefines a convex “ball” or radiused edge 25; wherein the plurality ofinterior segments are assembled so that the convex ball or radiused edge25 of one or more of the interior segments is received within theconcave groove 23 of an adjacent interior segment; and a cooling fluidmanifold 40 in fluid communication with the inlet 24 and outlet 26 ofeach interior segment with the cooling fluid manifold 40 having coolingfluid inlet 41 and outlet 42.

In another aspect, a preferred modular furnace cooling wall 100 of thepresent disclosure further comprises one or more end segments 50 havinga first side defining either a concave groove or channel 23 or a convexball or radiused edge 25 and a second side defining a generally flatsurface 51.

In another aspect of a preferred modular furnace cooling wall 10 of thepresent disclosure, the one or more end segments 50 is/are assembled tothe side or sides of the assembled interior segments 20 wherein thegenerally flat surface 51 of the end segment 50 is disposed as an outernarrow sidewall of the modular furnace cooling wall 10.

In another aspect of a preferred modular furnace cooling wall 10 of thepresent disclosure, the first side of each of the one or more endsegments 50 defining either a concave groove or channel 23 or a convexball or radiused edge 25 is disposed with a mating side of one of theinterior segments 20.

In yet another aspect, a preferred modular furnace cooling wall 10 ofthe present disclosure further comprises mounting plate or bracket 60 towhich each of the interior segments 20 is removably pinned or otherwiseremovably attached.

In another aspect, a preferred modular furnace cooling wall of thepresent disclosure further comprises one or more support braces orbrackets 60 removably attached to one or more of the interior segments20 and/or end segments 50.

In another aspect of a preferred modular furnace cooling wall of thepresent disclosure, the modular furnace cooling wall 10 defines a curvedwall, a semi-circular wall, a circular wall or an enclosed wall theperimeter of which defines a geometric or non-geometric shape.

A preferred interior segment 20 of a modular furnace cooling wall 10 ofthe present disclosure, comprises: a generally rectilinear or any shapedhousing which defines and houses a cooling fluid conduit having an inlet24 and an outlet 26; wherein a first side of each interior segmentdefines a concave groove or channel 23; wherein a second side of eachinterior segment defines a convex “ball” or radiused edge 25; whereinthe plurality of the interior segments may be assembled so that theconvex ball or radiused edge 25 of one or more of the interior segmentsis received within the concave groove 23 of an adjacent segment 20.

A preferred end segment 50 of a modular furnace cooling wall 10 of thepresent disclosure, comprises: a generally rectilinear or any shapedhousing which defines and houses a cooling fluid conduit having an inletand an outlet; a first side defining either a concave groove or channel23 or a convex ball or radiused edge 25 and a second side defining agenerally flat surface 51.

In another aspect of a preferred end segment of a modular furnacecooling wall 10 of the present disclosure, the one or more end segments50 is/are assembled to the side or sides of assembled any interiorsegments 20, wherein the generally flat surface 51 of the end segment 50is disposed as an outer narrow sidewall of the modular furnace coolingwall 10.

In yet another aspect of a preferred end segment 50 of a modular furnacecooling wall 10 of the present disclosure, the first side of the endsegment 50 defining either a concave groove or channel 23 or a convexball or radiused edge 25 is disposed with a mating side of one of aninterior segment 20.

In yet another aspect of a preferred end segment 50 of a modular furnacecooling wall 10 of the present disclosure, the inlets 24 and outlets 26of each segment 20, 50 are removably installed in fluid communicationwith a cooling fluid manifold 40 of the modular furnace cooling wall 10.

In another aspect of a preferred end segment 50 of a modular furnacecooling wall 10 of the present disclosure, each segment 20, 50 isremovably pinned or otherwise removably attached to mounting plate orbracket 60.

In another aspect of preferred end and/or interior segments 20, 50 of amodular furnace cooling wall 10 of the present disclosure, each segment20, 50 is removably attached to one or more support braces or supportbrackets 60.

In another aspect of preferred end and/or interior segments 20, 50 of amodular furnace cooling wall 10 of the present disclosure, each segment20, 50 forms a part of the modular furnace cooling wall 10 that definesa curved wall (of any radius), a semi-circular wall (of any radius), acircular wall (of any radius) or an enclosed wall the perimeter of whichdefines a geometric or non-geometric shape.

Additional aspects of a preferred modular furnace cooling wall 10 of thepresent disclosure include simplified assembly, reduced copperthickness, less overall weight due to reduced casting sizes but with allthe benefits of large cast furnace panels.

Further aspects of a preferred modular furnace cooling wall 10 of thepresent disclosure include that the segments 20, 50 may be made from anysuitable material including, copper, steel or other metal; the ball andsocket system components for connecting the furnace cooling wallsegments maybe machined from any material, at any length and width;drilled, cross drilled and plugged to form a circuit; cooling fluidcircuits may be connected by pipe, pipe fittings and/or hoses for thepurpose of “jumping” or “bypassing” a damaged furnace cooling wallsegment a damaged circuit.

Yet additional aspects of a preferred modular furnace cooling wall 10 ofthe present disclosure include: (1) single and/or multiple cast incooling fluid pipe circuits in each segment of any pipe diameter or pipematerial; (2) specially designed ball and socket connection betweensegments to allow a curved or enclosed wall of virtually any radius orshape to be formed; (3) segments and panels to any length, width orthickness; (4) faces of the segments may be with or without slagretainers or shelves; (5) the segments may be cast from any suitablematerial such as copper or steel or other metal; (6) the preferred balland socket joint between segments creates a weld seam and allows forthermal expansion; (7) Steel back plate and connections for rigidity,mounting and weldability; (8) cooling fluid circuits connected bybaffled header of any material and (9) for use in all ferrous andnon-ferrous metal making facilities.

Further aspects of a preferred modular furnace cooling wall of thepresent disclosure include faces of the modular wall 10 that may be asmooth face, slag pockets, refractory shelf and/or frame and brickconstructions as shown in U.S. Pat. No. 9,102,990 (incorporated byreference herein); the ability to incorporate features of largercastings i.e., thermocouples, etc., decreased production/delivery time;repairable wall segments; the ability to sell spares and/or “repairkits”; simple installation similar to pipe panels.

It will be appreciated that this background description has been createdby the inventors to aid the reader, and is not to be taken as anindication that any of the indicated problems were themselvesappreciated in the art. While the described principles can, in somerespects and embodiments, alleviate the problems inherent in othersystems, it will be appreciated that the scope of the protectedinnovation is defined by the attached claims, and not by the ability ofany disclosed feature to solve any specific problem noted herein.

What is claimed is:
 1. A modular furnace cooling wall, comprising: aplurality of segments wherein each interior segment houses or defines acooling fluid conduit having an inlet and an outlet; wherein a firstside of each segment defines a concave groove or channel; wherein asecond side of each segment defines a convex edge; and wherein theplurality of segments are assembled so that the convex edge of one ormore of the segments is received within the concave groove of anadjacent segment.
 2. The modular furnace cooling wall of claim 1 furthercomprising one or more end segments having a first side defining eithera concave groove or channel or a convex edge and a second side defininga generally flat surface.
 3. The modular furnace cooling wall of claim 2wherein at least one of the one or more end segments is assembled to anouter side of an assembled segment, wherein the generally flat surfaceof the end segment is disposed as an outer narrow sidewall of themodular furnace cooling wall.
 4. The modular furnace cooling wall ofclaim 2 wherein the first side of each of the one or more end segmentsdefining either a concave groove or channel or a convex edge isassembled to a mating side of one of the plurality of segments.
 5. Themodular furnace cooling wall of claim 1 further comprising a mountingplate or bracket to which each of the segments is removably pinned orotherwise removably attached.
 6. The modular furnace cooling wall ofclaim 2 further comprising one or more support braces or bracketsremovably attached to one or more of the segments or end segments. 7.The modular furnace cooling wall of claim 1 wherein the modular furnacecooling wall defines a curved wall, a semi-circular wall, a circularwall or an enclosed wall the perimeter of which defines a geometric ornon-geometric shape.
 8. The modular furnace cooling wall of claim 1further comprising a cooling fluid manifold in fluid communication withthe inlet and outlet of each segment.
 9. The modular furnace coolingwall of claim 2 further comprising a cooling fluid manifold in fluidcommunication with the inlet and outlet of each segment and end segment.10. An interior segment of a modular furnace cooling wall, the interiorsegment comprising: a housing which defines and houses a cooling fluidconduit having an inlet and an outlet; a first side of the housingdefining a concave groove or channel; and a second side of the housingdefining a convex edge.
 11. An end segment for a modular furnace coolingwall, the end segment comprising: a generally rectilinear housing whichdefines and houses a cooling fluid conduit having an inlet and anoutlet; a first side of the housing defining either a concave groove orchannel or a convex edge; and a second side defining a generally flatsurface.
 12. A modular furnace cooling wall, comprising: a plurality ofgenerally rectilinear wall segments wherein each wall segment houses ordefines a cooling fluid conduit having an inlet and an outlet; whereineach wall segment has planar first and second sides that are eachbeveled; and wherein the plurality of wall segments are assembled andsecured together to form a straight, curved, angled or enclosed wall.